Method of Producing Sportsball with Sculptural Ball Surface

ABSTRACT

A method of manufacturing a sports ball includes the steps of: providing a ball body having a valve stem formed thereat; providing a plurality of cover panels; integrally forming a plurality of sculptural bumps on at least a portion of one of the cover panels to form a sculptural ball surface of the cover panel; and overlapping the cover panels on said ball body to form a ball carcass in a stitch-less manner. Accordingly, the sculptural bumps are raised above an outer panel surface of the cover panel without applying a depression force to indent on the outer panel surface of the cover panel. The cover panels are interlocked and bonded with each other edge-to-edge to enclose the ball body inside the ball carcass.

NOTICE OF COPYRIGHT

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to any reproduction by anyone of the patent disclosure, as itappears in the United States Patent and Trademark Office patent files orrecords, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a sportsball, and more particular to amethod of producing a sportsball with sculptural ball surface thatcreates maximum grip and speed of the sportsball and enhances theaesthetic appearance of the sportsball.

2. Description of Related Arts

A conventional sports ball, such as a conventional soccer ball, usuallycomprises a ball bladder, an inner lining, and a ball casing. The ballcasing comprises a plurality of cover panels attached on the ballbladder, wherein each of the cover panels is usually stitched toadjacent cover panels for forming a substantially round sports ball.Accordingly, the cover panels can be made of leather or rubber. Thecover panels, being stitched onto the ball bladder, involve expensiveand time-consuming manufacturing procedures, yet the resulting sportsball may not have the optimal roundness.

The leather made cover panels are durable and flexible material made bythe tanning of animal rawhide and skin. Each of the leather made coverpanels has a plurality of different sized grains naturally formed on thepanel surface and having breathability. Accordingly, the sports ballwith the leather made cover panels, such as basketball, is mainly forindoor activity. It is known that water and moisture is not good forleather. If the leather made cover panels get wet and then dries, thecover panels can crack and dry out. In other words, most indoor sportsballs are not made by the leather made cover panels. In addition, inorder to enhance the aesthetic appearance of the sports ball, a logo ordesign can be printed on the cover panels. However, the logo or designcannot be perfectly printed on the surface of the cover panel because ofthe naturally formed gains.

On the other hand, the rubber made cover panels can solve the abovementioned problems of the leather made cover panels. Accordingly, therubber made cover panels are durable and waterproof such that theoutdoor sports ball, such as soccer ball, is made by the rubber madecover panels. Furthermore, the rubber made cover panel has a smoothsurface, such that the logo or design can be easily printed on therubber made cover panel. However, the major drawback of the rubber madecover panel is that there is no grain formed on the smooth panelsurface. Therefore, the sports ball with the rubber made cover panelswill substantially reduce the surface friction, such that the sportsball with the rubber made cover panels is too slippery and is hard tocontrol. The ball manufacturer will intentionally form the grains on therubber made cover panels by pressing a plurality of fine grooves to beindented on the panel surface to form a “texture” thereon. However, theindented grooves will substantially reduce the aesthetic appearance oreven destroy the logo or design printed on the sports ball.

In particular, the manufacturing process of the cover panel will becomplicated to involve the formation of the texture. The texture must beformed on the panel surface of the cover panel before the cover panelsare attached on the ball bladder. Therefore, the grains at the edge ofthe cover panel will be partially cut. Especially, when the cover panelsare attached edge to edge, the texture at the edges of the cover panelswill be damaged. In other words, when the edges of the cover panels arepressed to form the channels of the sports ball, the grains will bedisappeared at the channels of the sports ball.

U.S. Pat. No. 8,388,476 to Tsung Ming OU, who is the applicant of thepresent invention, disclosed a sports ball which comprises a ball pocketconstructed to have a true roundness shape and to receive the inflatablebladder therein. Therefore, when the inflatable bladder is inflated, theball pocket retains a true roundness shape of the inflatable bladder.

U.S. Pat. No. 6,650,067 to Tsung Ming OU, who also is the applicant ofthe present invention, disclosed a sports ball which comprises anexterior web layer integrally adhered on an outer surface of theinflatable bladder. Therefore, when the inflatable bladder is inflated,the exterior web layer retains a true roundness shape of the inflatablebladder.

SUMMARY OF THE PRESENT INVENTION

The invention is advantageous in that it provides a method of producinga sports ball with a sculptural ball surface that creates maximum gripand speed of the sportsball and enhances the aesthetic appearance of thesportsball.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein the sculpturaldesign and pattern can be selectively formed on the sportsball surfacenot only to increase the frictional surface but also to enhance theaesthetic appearance of the sportsball.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein a plurality ofsculptural bumps (or pimples) are raised above an outer panel surface ofthe cover panel to form the sculptural ball surface to enhance the gripand speed of the sportsball.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein no depression forceis required for applying on the outer panel surface of the cover panelin order to indent the outer panel surface of the cover panel. In otherwords, there is no damage on the outer panel surface of the cover panelin order to form the sculptural ball surface.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein the manufacturingmethod is simple, cost-effective, and efficient. In other words, thepresent invention provides an optimal method of producing a largequantity of sports ball in a relatively short period of time.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein the sports ball canbe manufactured into a wide variety of ball types, so as to facilitatewidespread applications of the present invention. For example, thesports ball can be manufactured as a soccer ball, an America football,or even a volley ball.

Another advantage of the invention is to provide a method of producing asports ball with a sculptural ball surface, wherein no expensive orcomplicated structure is required to employ in the present invention inorder to achieve the above mentioned objects. Therefore, the presentinvention successfully provides an economic and efficient solution forproviding a secure and reliable configuration for detachably mountingadditional accessories at the firearm with compact and ergonomic design.

Additional advantages and features of the invention will become apparentfrom the description which follows, and may be realized by means of theinstrumentalities and combinations particular point out in the appendedclaims.

According to the present invention, the foregoing and other objects andadvantages are attained by a method of manufacturing a sports ball,comprising the following steps.

(A) Provide a ball body having a valve stem formed thereat.

(b) Provide a plurality of cover panels.

(c) Integrally form a plurality of sculptural bumps on at least aportion of one of the cover panels to form a sculptural ball surface ofthe cover panel, wherein the sculptural bumps are raised above an outerpanel surface of the cover panel without applying a depression force toindent on the outer panel surface of the cover panel.

(d) Overlap the cover panels on the ball body to form a ball carcass ina stitch-less manner, wherein the cover panels are interlocked andbonded with each other edge-to-edge to enclose the ball body inside theball carcass, wherein one of the cover panels has a valve hole aligningwith the valve stem of the ball body.

In accordance with another aspect of the invention, the presentinvention comprises a sports ball which comprises a ball body having avalve stem formed thereat, a plurality of cover panels, and a sculpturalarrangement.

The cover panels are overlappedly laminated on the ball body to form aball carcass in a stitch-less manner, wherein the cover panels areinterlocked and bonded with each other edge-to-edge to enclose the ballbody inside the ball carcass, wherein one of the cover panels has avalve hole aligning with the valve stem of the ball body.

The sculptural arrangement has a plurality of sculptural bumpsintegrally formed on at least a portion of one of the cover panels toform a sculptural ball surface of the cover panel that create maximumgrip and speed of the sports ball, wherein the sculptural bumps areraised above an outer panel surface of the cover panel without applyinga depression force to indent on the outer panel surface of the coverpanel.

Still further objects and advantages will become apparent from aconsideration of the ensuing description and drawings.

These and other objectives, features, and advantages of the presentinvention will become apparent from the following detailed description,the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a sports ball according to a preferredembodiment of the present invention.

FIG. 2 is a schematic diagram illustrating the manufacturing process ofthe sports ball according to the above preferred embodiment of thepresent invention.

FIG. 3 is a flow diagram illustrating the manufacturing process of thesports ball according to the above preferred embodiment of the presentinvention.

FIG. 4 illustrates the formation of the sculptural ball surface of thecover panel according to the above preferred embodiment of the presentinvention.

FIG. 5 illustrates an alternative mode of the formation of thesculptural ball surface of the cover panel according to the abovepreferred embodiment of the present invention.

FIG. 6 illustrates an alternative mode of the ball pocket of the sportsball according to the above preferred embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description is disclosed to enable any person skilled inthe art to make and use the present invention. Preferred embodiments areprovided in the following description only as examples and modificationswill be apparent to those skilled in the art. The general principlesdefined in the following description would be applied to otherembodiments, alternatives, modifications, equivalents, and applicationswithout departing from the spirit and scope of the present invention.

Referring to FIGS. 1 to 3 of the drawings, a sports ball and itsmanufacturing method thereof according to a preferred embodiment of thepresent invention is illustrated, wherein the sports ball is shown as asoccer ball as an example. The sports ball comprises a ball body 10, aplurality of cover panels 20, and a sculptural arrangement 30.

The ball body 10, having a valve stem 101 formed thereat, comprises aninflatable bladder 11 and a ball pocket 12, which is constructed to havea true roundness shape, having an interior cavity receiving theinflatable bladder 11 therein, wherein when the inflatable bladder 11 isinflated, the ball pocket 12 retains a true roundness shape of theinflatable bladder 11.

Accordingly, the ball pocket 12 comprises a plurality of ball pocketleaves 121 integrally connected with each other. Practically, the fabricmade ball pocket 12 is able to form a spherical body that the ballpocket 12 is constructed to have a true roundness shape so as to retaina maximum diameter of the inflatable bladder 11 after it is inflated.

The ball pocket 12 is preferred to be made of fabric material having adurability, stretchability and adhesiveablility. Preferably, the ballpocket 12 can be made of a mixture fabric mixed with cotton andpolyester because the cotton has a good stretchability and is able toabsorb adhesive material and the polyester is durable and has a strongstrength that is able to resist strain when the inflatable bladder 11 isinflated.

The inflatable bladder 11 is disposed in the ball pocket 12 which has asize slightly bigger than the inflatable bladder 11 in such a mannerthat when the inflatable bladder 11 is inflated, an outer sphericalsurface of the inflatable bladder 11 is preferred to be slightly spacedapart from an inner spherical surface of the ball pocket 12 to form anair cushion layer therebetween. The air cushion layer is adapted forproviding a cushion effect for the stitching ball to provide a softnessfor the stitching ball and tolerate heavier impact thereon.

The cover panels 20 are overlappedly laminated on the ball body 10 toform a ball carcass in a stitch-less manner, wherein the cover panels 20are interlocked and bonded with each other edge-to-edge to enclose theball body 10 inside the ball carcass, wherein one of the cover panels 20has a valve hole 201 aligning with the valve stem 101 of the ball body10. Accordingly, the cover panels 20 serve as the cushioning panels ofthe sports ball.

The sculptural arrangement 30 has a plurality of sculptural bumps 31integrally formed on at least a portion of one of the cover panels 20 toform a sculptural ball surface of the cover panel 20 that create maximumgrip and speed of the sports ball, wherein the sculptural bumps 31 areraised above an outer panel surface of the cover panel 20 withoutapplying a depression force to indent on the outer panel surface of thecover panel 20.

Accordingly, the method of manufacturing a sports ball comprises thefollowing steps.

(1) Provide the ball body 10.

(2) Provide a plurality of cover panels 20. Preferably, only six coverpanels 20 are provided to form the soccer ball.

(3) Integrally form the sculptural bumps 31 on at least a portion of oneof the cover panels 20 to form the sculptural ball surface of the coverpanel 20.

(4) Overlap the cover panels 20 on the ball body 10 to form the ballcarcass in a stitch-less manner. Preferably, the cover panels 20 arelaminated on the ball body 10 to form the ball carcass in a stitch-lessmanner. Accordingly, the ball carcass is vulcanized to form an integralspherical carcass around the ball body 10 to provide a cushion effectfor the sports ball at any point thereof. Note that the heat treatment(vulcanization) can be performed by conventional heating machine, suchas a vulcanizing machine.

It is worth mentioning that the edge portion of each of the cover panels20 is slanted that a top surface of the edge portion of the cover panel20 downwardly and inclinedly extends a bottom surface thereof.Therefore, when the cover panels 20 are attached onto the ball body 10edge-to-edge, the edge portions of the two adjacent cover panels 20 forman indented channel on the ball carcass. In other words, the edgeportions of the adjacent cover panels 20 form the beveled seams for thecover panels 20 attaching onto the ball carcass edge-to-edge.Preferably, the edge portion of the cover panel 20 is trimmed to formthe slanted edge portion. Alternatively, the ball carcass is pressed ina mold along the edge portions of the cover panels 20 to form theindented channels on the ball carcass.

In order to manufacture the ball body 10, the step (1) further comprisesthe following steps.

(1.1) Form the ball pocket 12, which is constructed to have a trueroundness, having the interior cavity. The ball pocket 12 is made by thesteps of:

(1.1.1) providing a parent bladder having a true roundness shape afterthe parent bladder is inflated, wherein the parent bladder has the samesize and shape of the inflatable bladder 11;

(1.1.2) overlapping a plurality of pocket panels 121 on the parentbladder at a position that edge portions of the pocket panels 121 areoverlapped with edge portions of the adjacent pocket panels 121, whereinone of the pocket panels 121, having a valve hole, is remainedunattached to form an inlet opening of the ball pocket 12;

(1.1.3) heat-treating the pocket panels 121 to integrally bond the ballpanels 121 together to form a hollow round pocket body having the inletopening provided thereon; and

(1.1.4) removing the parent bladder from the hollow round pocket bodythrough the inlet opening after the parent bladder is deflated, so as toform the ball pocket 12.

(1.2) Dispose the inflatable bladder 11 in the ball pocket 12, whereinwhen the inflatable bladder 11 is inflated, the ball pocket 12 retains atrue roundness shape of the inflatable bladder 11. It is worthmentioning that after the inflatable bladder 11 is disposed in the ballpocket 12 through the inlet opening thereof, the inlet opening is sealedby attaching the unattached pocket panel 121 at a position that thevalve hole 201 is aligned with the valve stem 101 to sealedly enclosethe interior cavity to form the ball body 10.

FIG. 6 illustrates an alternative mode of forming the ball pocket 12′which comprises an exterior web layer 121′, which is integrally attachedon an outer surface of the inflatable bladder 11, and comprising atleast an elongated strengthened thread 122′ evenly wound around theouter surface of the inflatable bladder 11 such that the web layer 121′embraces the inflatable bladder 11 for resisting stress and impact forceapplied to the inflatable bladder 11. In order to enable thestrengthened threads 122′ being permanently affixed on the outer surfaceof the inflatable bladder 11, before winding onto the inflatable bladder11, the strengthened threads 122′ are coated with glue for adhering ontothe outer surface of the inflatable bladder 11 and each other. Moreover,the inflatable bladder 11 with the adhering strengthened threads 122′thereon are together cured by heating in a mold, so that the adheringstrengthened threads 122′ will be hardened to form the exterior weblayer 121′ which is permanently united with the inflatable bladder 11integrally.

Accordingly, the step (1.1) further comprises the steps of:

(1.1.1′) applying adhesive along the strengthened threads 122′;

(1.1.2′) evenly winding at least an elongated strengthened thread 122′around the outer surface of the inflatable bladder 11 to form the weblayer 121′, such that the web layer 121′ embraces the inflatable bladder11 for resisting stress and impact force applied to the inflatablebladder 11; and

(1.1.3′) hardening the strengthened threads 122′ by heat to form theexterior web layer 121′ which is permanently united with the inflatablebladder 11 integrally.

As it is mentioned above, there are six cover panels 20 overlappedlylaminated on the ball body 10 to form the ball carcass in a stitch-lessmanner. In particular, the cover panels 20 are interlocked and bondedwith each other edge-to-edge to enclose the ball body 10 inside the ballcarcass.

According to the preferred embodiment, the step (2) further comprises astep of cutting the cover panel 20 into a predetermined shape. Each ofthe cover panels 20 has a “X” configuration to define a center panelportion 21 and four panel extension portions 22 outwardly extended fromthe center panel portion 21. Each of the cover panels 20 further has aplurality of curved edges 23 and at least a straight edge 24 extendedfrom one of the curved edges 23. In particular, at least one curved edge23 and at least one straight edge 24 are formed at each of the panelextension portions 22 of the cover panels 20.

Having the “X” configuration of the cover panel 20 with the curved andstraight edges 23, 24, minimum numbers of cover panel 20 can be used toform the ball carcass not only for simplifying the manufacturing processof the sports ball but also for enhancing the true roundness for thesports ball at any point thereof. It is worth mentioning that the curvededges 23 and the straight edges 24 of the cover panels 20 are alignedwith each other to interlock the cover panels 20.

Furthermore, the step (2) further comprises the steps of:

(2.1) providing a cushioning layer 25, wherein the cushioning layer 25is made of foam material provide a uniform cushion effect to the sportsball for ensuring uniform performance thereof when the sports ball isactually in use in a ball game;

(2.2) attaching a skin layer 26 on the top side of the cushioning layer25, wherein the skin layer 26 is made of durable and waterproofmaterial, such as rubber; and

(2.3) attaching a backing layer 27 at the bottom side of the cushioninglayer 25 to form the cover panel 20. Accordingly, the backing layer 27can be made of fabric to enhance the strength of the cover panel 20 andto ensure the cover panel 20 to be laminated on the ball body 10. Inother words, the cushioning layer 25 is sandwiched between the skinlayer 26 and the backing layer 27.

In addition, the step (2) further comprises a step of forming a logoand/or design pattern on the skin layer 26. Accordingly, the logo and/ordesign pattern in different colors can be coated or printed on the skinlayer 26. It is worth mentioning that the skin layer 26 provides a flatand smooth surface, such that the logo and/or design pattern can beeasily printed on the skin layer 26. Preferably, the logo and/or designpattern can be coated on the skin layer 26 by screen printing. Forexample, ink is forced to pass through a screen stencil to coat the inkon the skin layer 26 in order to form the logo and/or design pattern.

As shown in FIG. 4, in order to form the sculptural ball surface of thecover panel 20, the step (3) further comprises the following steps.

(3.1) Place a treatment layer 40 on top of the cover panel 20, whereinthe treatment layer 40 comprises a mesh layer 41 having a plurality ofmeshes 411 thereon, and a sculptural layer 42 formed at a bottom side ofthe mesh layer 41. In particular, the sculptural layer 42 is made ofsculptural substance, such as adhesive, formed at the bottom side of themesh layer 41 and filled at the meshes 411 of the mesh layer 41.

Accordingly, the mesh layer 41 is a thin film made of non-stickmaterial. The sculptural layer 42 also is a thin film overlapped at thebottom side of the mesh layer 41 to define a film portion at the bottomside of the mesh layer and a plurality of protruded portions filled atthe meshes 411 of the mesh layer 41. In other words, the thickness ofeach of the protruded portions of the sculptural layer 42 is larger thanthe thickness of the film portion of the sculptural layer 42. Thethickness of each of the protruded portions of the sculptural layer 42is the total thickness of the film portion of the sculptural layer 42and the thickness of the mesh layer 41.

(3.2) Integrally bond the sculptural layer 42 on the outer panel surfaceof the cover panel 20, such that the sculptural substances filled at themeshes 411 of the mesh layer 41 forms the sculptural bumps 31 on theouter panel surface of the cover panel 20 respectively. Preferably, heatis gently applied onto the treatment layer 40 to detach the sculpturallayer 42 from the mesh layer 41 and to integrally bond the sculpturallayer 42 on the outer panel surface of the cover panel 20. As shown inFIG. 4, a heater with an elongated heater head is reciprocatingly movedon the treatment layer 40 in order to evenly apply the head on thetreatment layer 40. Once the sculptural substance is heated, thesculptural layer 42 will be detached from the mesh layer 41 and will beintegrally bonded on the outer panel surface of the cover panel 20. Itis worth mentioning that relatively low heat, preferably 40-50° C., isapplied onto the treatment layer 40.

The sculptural substance is preferably PU composite ink to be formed onthe bottom side of the mesh layer 41, such that the sculptural layer 42will form a clear coat on the outer panel surface of the cover panel 20.It is worth mentioning that the sculptural substance can be transparentor configured with a desired color to be coated on the outer panelsurface of the cover panel 20.

(3.3) Remove the mesh layer 41 on top of the cover panel 20 to leave thesculptural layer 41 on the outer panel surface of the cover panel 20.Accordingly, once the sculptural layer 42 is integrally bonded on theouter panel surface of the cover panel 20, the non-stick mesh layer 41can be easily removed from the sculptural layer 42, such that thesculptural substances, which are previously filled at the meshes 411 ofthe mesh layer 41, will integrally protrude out from the outer panelsurface of the cover panel 20 so as to form the sculptural bumps 31 onthe outer panel surface of the cover panel 20 respectively.

According to the preferred embodiment, the sculptural bumps 31 can beevenly formed on the entire outer panel surface of the cover panel 20,such that the entire outer panel surface of the cover panel 20 will formthe sculptural ball surface. It should be appreciated that thesculptural bumps 31 can be only formed on a portion of the outer panelsurface of the cover panel 20, such as only the logo thereon, such thatonly the logo surface will form the sculptural ball surface. It is worthmentioning that the sculptural layer 42 also serves as a protectionlayer to protect the logo and/or design pattern on the skin layer 26 ofthe cover panel 20.

As shown in FIG. 4, the meshes 411 are orderly formed at the mesh layer41 in a wavy configuration to sculpture the sculptural bumps 31 in awavy pattern on the cover panel 20. Furthermore, each of the meshes 411has a quadrilateral shape to sculpture each of the sculptural bumps 31with quadrilateral shape. It should be appreciated that the sizes andshapes of the meshes 411 can be changed to sculpture differentsculptural bumps 31 in different patterns and different shapes. Forexample, each of the sculptural bumps 31 can have a semi-spherical shapeprotruded out of the outer panel surface of the cover panel 20. It isworth mentioning that the sculptural bumps 31 are formed by thesculptural substances, wherein no depression force is required forapplying on the outer panel surface of the cover panel 20 in order toindent the outer panel surface of the cover panel 20. In other words,there is no damage on the outer panel surface of the cover panel 20 inorder to form the sculptural ball surface.

FIG. 5 illustrates an alternative method to form the sculptural ballsurface, wherein the step (3) comprises the following steps.

(3.1′) Place a mesh layer 41′ on top of the cover panel 20, wherein themesh layer 41′ has a plurality of meshes 411′ thereon.

(3.2′) Evenly apply a sculptural substance 42′ on the mesh layer 41°that the sculptural substance 42′ passes through the meshes 411′ to beintegrally bonded on the outer panel surface of the cover panel 20 toform the sculptural bumps 31 thereon. Accordingly, the sculpturalsubstance 42′ is in liquid form when applying on the mesh layer 41′ andis in solid form after dried. In other words, the fluid sculpturalsubstance 42′ is directly applied on the mesh layer 41′ such that thefluid sculptural substance 42′ will fill into the meshes 411′ and willcontact with the outer panel surface of the cover panel 20. Once thefluid sculptural substances 42′ at the meshes 411 are dried, the fluidsculptural substances 42′ will integrally bond on the outer panelsurface of the cover panel 20 to form the sculptural bumps 31 thereon.

The sculptural substance 42′ is preferably PU composite ink to beapplied on the outer panel surface of the cover panel 20, such that thesculptural substance 42′ will form a clear coat on the outer panelsurface of the cover panel 20. It is worth mentioning that thesculptural substance 42′ can be transparent or configured with a desiredcolor to be coated on the outer panel surface of the cover panel 20.

Accordingly, the sculptural substance 42′, such as the PU composite ink,is coated on the outer panel surface of the cover panel 20 by screenprinting. In other words, the mesh layer 41′ serves as a screen stencilto enable the sculptural substance 42′ to pass through the meshes 411′and to apply on the outer panel surface of the cover panel 20.Preferably, the sculptural substance 42′ is sprayed on the mesh layer41′ via a spraying head to evenly apply the sculptural substance 42′ onthe mesh layer 41′ to the outer panel surface of the cover panel 20.

The step (3.2′) further comprises the following steps.

(3.2.1′) Sweep the sculptural substance 42′ on the mesh layer 41′ toensure the sculptural substance 42′ to be evenly applied on the meshlayer 41′ and to be evenly penetrated through the meshes 411′ on theouter panel surface of the cover panel 20. Accordingly, a sweeper havingan elongated sweeping head is reciprocatingly moved on the mesh layer41′ to evenly apply the sculptural substance 42° on the mesh layer 41′and to ensure the sculptural substance 42′ to be filled at the meshes411′ of the mesh layer 41′.

(3.2.2′) Swab excessive sculptural substance on the mesh layer 41′ afterthe sculptural substance 42′ is applied on the outer panel surface ofthe cover panel 20. Once the sculptural substances 42′ are filled at themeshes 411′ of the mesh layer 41′, the sweeping head can reciprocatinglymove on the mesh layer 41° to swab excessive sculptural substance on themesh layer 41′. Accordingly, the sweeping and swabbing actions in thesteps (3.2.1′) and (3.2.2′) can be repeatedly preformed until thesculptural substances 42′ are filled at all the meshes 411′ of the meshlayer 41′ and no excessive sculptural substance leaves on the mesh layer41′.

(3.3′) Remove the mesh layer 41′ on top of the cover panel 20.Accordingly, the non-stick mesh layer 41′ can be easily removed from thesculptural substances 42′, such that the sculptural substances 42′,which are previously filled at the meshes 411′ of the mesh layer 41′,will integrally protrude out from the outer panel surface of the coverpanel 20 so as to form the sculptural bumps 31 on the outer panelsurface of the cover panel 20 respectively.

Furthermore, heat can be gently applied onto the cover panel 20 tointegrally bond the sculptural substances 42′ on the outer panel surfaceof the cover panel 20. It is worth mentioning that relatively low heat,preferably 40-50° C., is applied onto the sculptural substance 42′ inorder to integrally bond the sculptural substance 42′ on the outer panelsurface of the cover panel 20.

Likewise, the meshes 411′ are orderly formed at the mesh layer 41′ in awavy configuration to sculpture the sculptural bumps 31′ in a wavypattern on the cover panel 20. Furthermore, each of the meshes 411′ hasa quadrilateral shape to sculpture each of the sculptural bumps 31 withquadrilateral shape. It should be appreciated that the sizes and shapesof the meshes 411′ can be changed to sculpture different sculpturalbumps 31 in different patterns and different shapes. It is worthmentioning that the sculptural bumps 31 are formed by the sculpturalsubstances, wherein no depression force is required for applying on theouter panel surface of the cover panel 20 in order to indent the outerpanel surface of the cover panel 20. In other words, there is no damageon the outer panel surface of the cover panel 20 in order to form thesculptural ball surface.

Accordingly, thousands of sculptural bumps 31 can be integrallyprotruded from the outer surface of the ball carcass, i.e. all the outerpanel surfaces of the cover panels 20, to substantially increase thesurface friction of the sports ball so as to maximize the grippingability of the sports ball. Therefore, the player, such as the soccerplayer, is able to easily control the sports ball and to accuratelyshoot the sports ball. In addition, an air channel is formed between thesculptural bumps 31 to enhance the aerodynamics of the sports ball. Inparticular, the wavy configuration of the sculptural bumps 31 willcreate the wavy air channel to enhance the speed of the sports ball,especially when the sports ball is spinning. It is worth mentioning thatthe sculptural bumps 31 are relatively light weight, such that theoverall weight of the sports ball will be determined without taking intoaccount of the weight of the sculptural bumps 31. Furthermore, the sizeof the sculptural bump 31 is adjustably controlled by the dimension,such as the depth, of the meshes 411, 411′ of the mesh layer 41, 41′.Accordingly, since the ball body 10 is constructed to have the ballpocket 12, 12′ to reinforce the entire ball structure and to have abetter flexibility and impact resisting ability, the cover panels 20serve as the cushioning panels for stress absorption. In addition, thecover panels 20 with the sculptural bumps 31 will provide a bettercontrol for the sports ball.

One skilled in the art will understand that the embodiment of thepresent invention as shown in the drawings and described above isexemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have beenfully and effectively accomplished. The embodiments have been shown anddescribed for the purposes of illustrating the functional and structuralprinciples of the present invention and is subject to change withoutdeparture from such principles. Therefore, this invention includes allmodifications encompassed within the spirit and scope of the followingclaims.

What is claimed is:
 1. A method of manufacturing a soccer ball,comprising the steps of: (a) providing a ball body having a valve stemformed thereat; (b) providing a plurality of cover panels; (c)integrally forming a plurality of sculptural bumps on at least a portionof one of said cover panels to form a sculptural ball surface of saidcover panel, wherein said sculptural bumps are raised above an outerpanel surface of said cover panel without applying a depression force toindent on said outer panel surface of said cover panel; and (d)overlapping said cover panels on said ball body to form a ball carcass,wherein said cover panels are bonded with each other to enclose saidball body inside said ball carcass, wherein one of said cover panels hasa valve hole aligning with said valve stem of said ball body.
 2. Themethod, as recited in claim 1, wherein said step (c) further comprisesthe steps of: (c.1) placing a treatment layer on top of said coverpanel, wherein said treatment layer comprises a mesh layer having aplurality of meshes thereon, and a sculptural layer formed at a bottomside of said mesh layer, wherein said sculptural layer is made ofsculptural substance formed at said bottom side of said mesh layer andfilled at said meshes of said mesh layer; (c.2) integrally bonding saidsculptural layer on said outer panel surface of said cover panel, suchthat said sculptural substances filled at said meshes of said mesh layerforms said sculptural bumps on said outer panel surface of said coverpanel respectively; and (c.3) removing said mesh layer on top of saidcover panel to leave said sculptural layer on said outer panel surfaceof said cover panel.
 3. The method, as recited in claim 2, wherein saidmesh layer is made of non-stick material, such that said mesh layer isremoved after said sculptural layer is applied on said outer panelsurface of said ball carcass.
 4. The method, as recited in claim 3,wherein said step (c.2) further comprises a step of applying heat onsaid treatment layer to detach said sculptural layer from said meshlayer and to integrally bond said sculptural layer on said outer panelsurface of said cover panel.
 5. The method, as recited in claim 4,wherein said meshes are orderly formed at said mesh layer in a wavyconfiguration to sculpture said sculptural bumps in a wavy pattern onsaid cover panel, wherein each of said meshes has a quadrilateral shapeto sculpture each of said sculptural bumps with quadrilateral shape. 6.The method, as recited in claim 1, wherein said step (c) furthercomprises the steps of: (c.1) placing a mesh layer on top of said coverpanel, wherein said mesh layer has a plurality of meshes thereon; (c.2)evenly applying a sculptural substance on said mesh layer that saidsculptural substance passes through said meshes to be integrally bondedon said outer panel surface of said cover panel to form said sculpturalbumps thereon; and (c.3) removing said mesh layer on top of said coverpanel.
 7. The method, as recited in claim 6, wherein said sculpturalsubstance is in liquid form when applying on said mesh layer and is insolid form after dried.
 8. The method, as recited in claim 7, whereinsaid mesh layer is made of non-stick material, such that said mesh layeris removed after said sculptural substance is applied on said outerpanel surface of said ball carcass through said meshes.
 9. The method,as recited in claim 7, wherein said step (c.2) further comprises thesteps of: (c.2.1) sweeping said sculptural substance on said mesh layerto ensure said sculptural substance to be evenly applied on said meshlayer and to be evenly penetrated through said meshes on said outerpanel surface of said cover panel; and (c.2.2) swabbing excessivesculptural substance on said mesh layer after said sculptural substanceis applied on said outer panel surface of said cover panel.
 10. Themethod, as recited in claim 8, wherein said meshes are orderly formed atsaid mesh layer in a wavy configuration to sculpture said sculpturalbumps in a wavy pattern on said cover panel, wherein each of said mesheshas a quadrilateral shape to sculpture each of said sculptural bumpswith quadrilateral shape.
 11. The method, as recited in claim 1, whereinsaid step (b) further comprises a step of forming six cover panels tointerlock with each other edge-to-edge to form said ball carcass,wherein each of said cover panels has a “X” configuration to define acenter panel portion and four panel extension portions, wherein each ofsaid cover panels has a plurality of curved edges and at least astraight edge extended from one of said curved edges.
 12. The method, asrecited in claim 2, wherein said step (b) further comprises a step offorming six cover panels to interlock with each other edge-to-edge toform said ball carcass, wherein each of said cover panels has a “X”configuration to define a center panel portion and four panel extensionportions, wherein each of said cover panels has a plurality of curvededges and at least a straight edge extended from one of said curvededges.
 13. The method, as recited in claim 6, wherein said step (b)further comprises a step of forming six cover panels to interlock witheach other edge-to-edge to form said ball carcass, wherein each of saidcover panels has a “X” configuration to define a center panel portionand four panel extension portions, wherein each of said cover panels hasa plurality of curved edges and at least a straight edge extended fromone of said curved edges.
 14. The method, as recited in claim 11,wherein said step (d) further comprises a step adhering said coverpanels on said ball body to form said ball carcass in a stitch-lessmanner so as to enclose said ball body inside said ball carcass, whereineach of said to cover panels comprises a skin layer, a backing layer,and a cushioning layer sandwiched between said skin layer and saidbacking layer, wherein said step (b) further comprises a step ofprinting a design pattern on said skin layer.
 15. The method, as recitedin claim 12, wherein said step (d) further comprises a step adheringsaid cover panels on said ball body to form said ball carcass in astitch-less manner so as to enclose said ball body inside said ballcarcass, wherein each of said cover panels comprises a skin layer, abacking layer, and a cushioning layer sandwiched between said skin layerand said backing layer, wherein said step (b) further comprises a stepof printing a design pattern on said skin layer.
 16. The method, asrecited in claim 13, wherein said step (d) further comprises a stepadhering said cover panels on said ball body to form said ball carcassin a stitch-less manner so as to enclose said ball body inside said ballcarcass, wherein each of said cover panels comprises a skin layer, abacking layer, and a cushioning layer sandwiched between said skin layerand said backing layer, wherein said step (b) further comprises a stepof printing a design pattern on said skin layer.
 17. A soccer ball,comprising: a ball body having a valve stem formed thereat; a pluralityof cover panels overlappedly laminated on said ball body to form a ballcarcass in a stitch-less manner, wherein said cover panels areinterlocked and bonded with each other edge-to-edge to enclose said ballbody inside said ball carcass, wherein one of said cover panels has avalve hole aligning with said valve stem of said ball body; and asculptural arrangement having a plurality of sculptural bumps integrallyformed on at least a portion of one of said cover panels to form asculptural ball surface of said cover panel that create maximum grip andspeed of said soccer ball, wherein said sculptural bumps are raisedabove an outer panel surface of said cover panel without applying adepression force to indent on said outer panel surface of said coverpanel.
 18. The soccer ball, as recited in claim 17, wherein saidsculptural bumps are orderly sculptured in a wavy pattern on said coverpanel, wherein each of said sculptural bumps are sculptured in aquadrilateral shape.
 19. The soccer ball, as recited in claim 18,wherein six of said cover panels are provided to interlock with eachother edge-to-edge to form said ball carcass, wherein each of said coverpanels has a “X” configuration to define a center panel portion and fourpanel extension portions, wherein each of said cover panels has aplurality of curved edges and at least a straight edge extended from oneof said curved edges, wherein each of said cover panels comprises a skinlayer, a backing layer, and a cushioning layer sandwiched between saidskin layer and said backing layer, wherein a design pattern is printedon said skin layer.
 20. The soccer ball, as recited in claim 19, whereinsaid ball body comprises an inflatable bladder and a ball pocket, whichis constructed to have a true roundness shape, having an interior cavityreceiving said inflatable bladder therein, wherein when said inflatablebladder is inflated, said ball pocket retains a true roundness shape ofsaid inflatable bladder, wherein said ball pocket comprises a pluralityof pocket panels which are overlappedly laminated with each other sideby side and are treated to form an integral spherical structure of saidball pocket so as to retain a true roundness shape of said inflatablebladder after said inflatable bladder is inflated.
 21. The soccer ball,as recited in claim 19, wherein said ball body comprises an inflatablebladder and a ball pocket, which is constructed to have a true roundnessshape, having an interior cavity receiving said inflatable bladdertherein, wherein when said inflatable bladder is inflated, said ballpocket retains a true roundness shape of said inflatable bladder,wherein said ball pocket comprises an exterior web layer, which isintegrally attached on an outer surface of said inflatable bladder,comprising at least an elongated strengthened thread evenly wound aroundsaid outer surface of said inflatable bladder such that said web layerembraces said inflatable bladder for resisting stress and impact forceapplied to said inflatable bladder.